Help your kids feel super this Halloween with a fun and easy superhero costume. This project involves very little sewing and recycles an old t-shirt so you don't have to spend a lot of money either.
Cut the cape fabric into a large rectangle. Save the leftover fabric for the mask and armband. Here is a list of layer sizes for different ages:12 months to 2T =36" x 16"; 3T to 5T =36" x 20"; 6 to 8 years =36" x 24"; 8 to 10 years =36" x 27".
For the cape, use liquid metal cloth. It can usually be found in the costume fabric section of most reputable fabric stores. Liquid metal fabric doesn't fray, so there's no need to worry about hemming or other more time-consuming sewing techniques. Other easy-to-work fabrics you might consider for your cape include flannel, fleece, knit, and some other costume fabrics. These may not have the same light, airy feel, but they'll do the trick.
Along the longest top edge of your cape, sew a basting stitch. This is essentially a very long straight stitch. Do not reinforce either end of this stitch when sewing. Then, gather the fabric together by gently pulling the bobbin thread on each side until the layer meets and meets in the center.
Cut the 1-1/2" ribbon. Make it double the length of the gathered end of the cape plus an extra inch.
Cut two 1” pieces of Velcro tape (Velcro). It basically has two sides, one with "hooks" (the rough, rough side); and the other side has "loops" (the smooth side). Separate the hooks from the loops on both pieces. Place the hook pieces (rough) on the right side of the folded ribbon, one inch from each end. Attach the Velcro pieces in place through a layer of tape. Sew a square around each piece of Velcro using a normal straight stitch.
Fold the ribbon back together, right sides in; sew around the three outer edges. Leave the bottom long edge raw/open. Turn right.
You should now have the two Velcro hooks sewn onto your strap, with the bottom of that strap open. Attach the two Velcro pieces to the top of the shirt. Sew the loop pieces in place on the shirt.
Slide the open end of the ribbon, Velcro side up, into the bottom of the cape. You want the wrong side of the layer (not the shiny side) to be facing up. Slide the gathered edge inside the ribbon. Then pin the gathered top of the cape inside the bottom edge of the tape. Sew in place.
Embellish the front of the shirt. We simply cut a shape out of felt (you can also use fleece or knit). I then used a needle and thread to hand sew the shape directly onto the shirt.
You can also use fabric glue if you don't want to hand sew.
To make the skin, print out the downloadable skin template (if you haven't already done so). Cut around the mask and cut out the eye holes. Use Coats &Clark Phoomph fabric reinforcement product. Follow the package directions and adhere the liquid hardware cloth to both sides of the Phoomph.
Use a pen to trace around the mask pattern directly onto the fabric covered Phoomph (Image 1). Use scissors to cut out the shape of the cloth mask. Cut a piece of bungee cord 15 inches long. Tie both ends of the string into the holes on the side of the mask (Image 2).
To make the bracelet print the downloadable bracelet template (if you haven't already done so). Next, cut out the pattern piece from your fabric covered Phoomph. Embellish the bracelet if desired with leftover felt fabrics; cut out the shape and sew directly onto your cuff.
Attach a 3” piece of Velcro. Separate the loop and hook the Velcro pieces, and sew them to opposite ends of your bracelet, one on the right side and one on the bottom wrong side.
Put on your cape, slide on the mask and adjust the armband. Now is the time to save the world..
